Three years after the Lights-Out project: How integration keeps Mercian Labels moving forward

When Mercian Labels first introduced its ambitious “Lights-Out Project” three years ago during LabelExpo Americas 2022, it caught the attention of the label industry. The vision was clear: to achieve a fully automated, digitally driven production workflow that could, quite literally, keep running with the lights out.

Fast forward to today, and the project has evolved into something even more powerful. Through close collaboration with CERM, ABG, and SCREEN, Mercian Labels has turned that vision into everyday reality — creating an operation where automation and integration drive performance, precision, and sustainable growth.

In a recent discussion between Andrew Strand, CERM’s Business Development Manager for the UK & Nordics, and Dr. Adrian Steele, Managing Director at Mercian Labels, the two reflected on how far the company has come since launching its automation journey — and where they’re heading next.

From "Lights-Out" to "Always-On"

The Lights-Out Project was Mercian’s first major step toward a fully integrated production environment. With CERM MIS as the central system, the company set out to connect digital presses, finishing lines, and management workflows into one cohesive ecosystem.

What once required multiple systems and manual data entries is now managed through a single source of truth. Orders flow seamlessly from CERM into production, through SCREEN’s digital presses and ABG’s finishing equipment, and back into reporting — without the need for human intervention at every step.

This level of automation has made day-to-day operations faster, leaner, and more consistent. But beyond efficiency, it has created visibility: every job, material, and production stage can now be tracked and analyzed in real time.

Integration as a foundation for growth

Today, Mercian Labels operates in a production environment where integration is not just a feature but the foundation. Through CERM’s partnerships with SCREEN and ABG, Mercian’s team benefits from synchronized data exchange, automated scheduling, and smart job management. As Adrian said, "I looked at smaller competitors to CERM, I looked at larger competitors. And for me, when I sort of made the choice, it was all about the integrations."

This ecosystem enables the company to handle a growing volume of short-run digital jobs while maintaining the same agility that made it successful in the first place. The integration between these technologies ensures that decisions are data-led, setup times are reduced, and every workflow is aligned with real-time capacity and demand.

A collaboration that keeps evolving

CERM’s philosophy of open integration plays a crucial role in making this setup possible. By collaborating with trusted industry partners like SCREEN and ABG, CERM gives converters like Mercian the flexibility to build connected workflows with best-in-class partners. "You can't achieve automation unless you've got those integrations. And we use lots of them, which it's a real, real-time saver," stated Adrian.

The combination of CERM, ABG, and Screen has created a truly end-to-end digital workflow — one where production data flows automatically from estimating and scheduling to printing and finishing, minimizing manual input and errors along the way.

What stands out most is how these integrations have matured over time. The system no longer just automates repetitive tasks; it actively enables strategic growth by providing the insights and control needed to scale efficiently.

Beyond technology: the human side of automation

Mercian’s journey shows that automation works best when it’s supported by the right mindset. The Lights-Out Project wasn’t only about machines running independently — it was about creating a culture that embraces continuous improvement and smarter ways of working.

The team’s commitment to process clarity and openness to change made it possible to evolve from concept to daily reality. Their experience highlights that digital transformation isn’t just about software; it’s about aligning people, processes, and technology toward a shared goal.

What’s next? Smarter decisions through data

With integration firmly in place, the next phase for Mercian Labels focuses on data intelligence and AI-driven automation. By using tools like CERM Smart BI and AI capabilities that help convert email traffic into actionable orders, the company continues to refine production insights, identify trends, and make faster, more informed decisions.

This shift from automation to intelligent optimization marks the next chapter of the Lights-Out journey — one where information and AI-driven insights are just as valuable as automation itself.

Two years after setting out to achieve a “lights out” operation, Mercian Labels has proven that automation and integration can coexist with flexibility and creativity. Supported by CERM MIS and its strong technology partnerships, Mercian continues to demonstrate how a connected workflow can drive growth, efficiency, and innovation in the modern label industry.

The Lights-Out Project may have started as an idea — today, it’s a reality that continues to evolve.